Coolant corrosiveness indicator

ABSTRACT

A fluid sensor for heat exchanger system includes a supporting device such as a tubular hose fitting for mounting the sensor in the system so that heat exchanging fluid circulated in the system comes into contact with the sensor. A window or sight glass is mounted in the supporting device along with corrodible separating means interposed between the sight glass and the heat exchanging fluid. A visual indicator such as a movable flap or a colored ball can be viewed through the sight glass when the separating means is ruptured or broken by corrosion. The viewing of the indicator provides an indication that the heat exchanging fluid has reached a certain corrosive state and requires replacement or treatment. In a preferred embodiment, the separating means is a metal diaphragm spaced from the sight glass. The diaphragm can be made of one corrodible metal while a ring in which the diaphragm is mounted can be made from a different nobler metal so that the diaphragm and ring form an anode and a cathode of a galvanic couple.

BACKGROUND OF THE INVENTION

This invention relates to fluid condition sensors or indicators intendedfor use in a heat exchanger system such as a radiator or airconditioning system.

A well known engine coolant for an automotive vehicle contains asolution of ethylene glycol and a small percentage of diethylene glycoldiluted with water to make an approximately 50--50 mixture or lowerdepending on the desired freezing point for the solution. Generally,manufacturers or distributors of ethylene glycol add one or morecorrosion inhibitors to the solution to protect the metal components ofthe engine cooling system, particularly the radiator. These inhibitorsare usually a mixture of one or more inorganic salts such as phosphates,borates, nitrates, nitrites, silicates or arsenates and organiccompound. The solution is usually buffered to a pH of 8 to 10 to reduceiron corrosion and to neutralize any glycolic acid.

It is very important that the coolant mixture in an engine coolingsystem contain 50 to 55% of properly inhibited ethylene glycol toprevent corrosion of conventional copper-brass radiators. Also, aluminumradiators have now come into use and such radiators are even moresusceptible to corrosion. The problem of corrosion can be caused simplyby the addition of ordinary water to the cooling system by a driver whenhe is low in coolant. For example, a reduction of the coolant mixture to33% ethylene glycol and 67% water will increase metal corrosionsignificantly, especially in higher temperature coolant systems.

U.S. Pat. No. 4,338,959 issued Jul. 13, 1982 to Borg-Warner Corporationteaches a device for the automatic addition of corrosion inhibitor to acooling system including an electronic control circuit having a probe orsensor which indicates corrosion rates in an engine cooling system andprovides a signal to a solenoid activating a control valve whichautomatically adds a controlled amount of corrosion inhibitors solutionto the cooling system. However, this known system has certaindisadvantages, one of which is the amount of room required to installthe system in a vehicle. For example, the system requires a containercapable of holding an adequate reserve charge of corrosion inhibitor.Also, there is a significant expense involved in providing this systemin a vehicle because of the cost of the corrosion inhibitor and otherrequired components.

U.S. Pat. No. 4,306,127 issued Dec. 15, 1981 to Robertshaw ControlsCompany describes a corrosion sensor having a housing containing anelectric switch mechanism. A switch actuator is held in one operatingposition by a corrosion sensing member formed from a disk of aluminumfoil that spans one end of the housing. The actuator moves to anotherswitch operating position when the aluminum foil ruptures through thecorrosion thereof caused by being exposed to a corrosive area. Aflexible diaphragm is carried by the housing in stacked engagingrelation with the aluminum disk and acts to prevent corrosive materialfrom entering the housing when the aluminum disk ruptures.

U.S. Pat. No. 4,736,628 issued Apr. 12, 1988 to V. S. Lynn describes atesting device for a car battery or radiator, which device includes atransparent box-like housing forming a partitioned chamber. There are aplurality of channels in which a plurality of balls having variousdensities are contained. The fluid to be tested enters the housingthrough a tubular element at the top. The number of floating balls inthe housing indicates the specific gravity of the fluid and the freezingand boiling point thereof.

Test results reported in a paper co-authorized by one of the presentinventors (Brian Cheadle) confirm that relatively high degrees ofcoolant depletion are required to initiate corrosion damage in aluminumcylinder head material compared to corrosion of a corrodible diaphragm.This paper entitled "Controlled Release of Inhibitors for ExtendedProtection of Aluminum Engine Cooling Systems" was published by theSociety of Automotive Engineers as Paper 820287 in 1983.

SUMMARY OF THE INVENTION

The present invention provides a rather inexpensive fluid conditionsensor which will provide a visual indication to the user that the heatexchanging fluid has reached a certain corrosive state. Generally, thedevice employs a sight glass or window through which an indicator of thecorrosive state can be seen or through which the heat exchanging fluidcan be seen. In the second version, the presence of the fluid behind thesight glass indicates a corrosive state. The sensor employs a corrodibleseparating mechanism such as a diaphragm or a coating on the sight glasswhich is normally interposed between the sight glass and the heatexchanging fluid and which is in contact with the heat exchanging fluidduring use of a sensor.

According to one aspect of the invention, a fluid condition sensor for aheat exchanger system includes support means for mounting the sensor ina system in such a manner that heat exchanging fluid circulated in asystem comes into contact with the sensor and a sight glass mounted inthe support means. There is a corrodible separating means interposedbetween a sight glass and the heat exchanging fluid and located so thatthe heat exchanging fluid contacts the separating means during use ofthe sensor. A visual indicator can be viewed through the sight glasswhen the separating means is removed, ruptured or broken by corrosion.The viewing of this indicator provides an indication that the heatexchanging fluid has reached a certain corrosive state.

According to another aspect of the invention, a corrosion sensor for aheat exchanger system includes support means for mounting the sensor ina system to enable the sensor to contact heat exchange fluid flowingthrough the system and a corrodible diaphragm mounted in the supportmeans where the fluid can contact one side of the diaphragm during useof the sensor. There is also a sight glass mounted in the support meanson the other side of the diaphragm, a normally empty chamber beingarranged between the diaphragm and the sight glass. The diaphragm isselected and constructed so as to corrode and rupture before the heatexchange fluid becomes so corrosive that it can cause significant damageto the heat exchange system. A rupture of the diaphragm causes the fluidto flow into the chamber and thereby indicates a need to change or treatthe heat exchange fluid.

In one preferred embodiment of this sensor, the support means is atubular hose fitting having an inlet and an outlet for the heatexchanging fluid and an opening in one side thereof in which thediaphragm and the sight glass are mounted. This preferred embodiment issuitable for installation as either original equipment in a vehiclecooling system or for subsequent installation after sale.

According to a further aspect of the invention, a corrosion sensor for aheat exchanger system includes supporting means for mounting the sensorin the system to enable the sensor to contact heat exchanging fluidflowing through the system and a visual indicator mounted in the supportmeans and movable from a first position indicating that the heatexchanging fluid is in a non-corrosive state to a second positionindicating that the fluid has become corrosive to at least a limiteddegree. There is also a corrodible release mechanism for holding theindicator in the first position and located so as to be immersed in theheat exchanging fluid during use of the sensor. A sight glass is mountedin or on the support means and the indicator is visible through thesight glass. The release mechanism corrodes and breaks when the fluidbecomes corrosive to at least a limited degree, thereby releasing theindicator so that it moves to the second position.

In a preferred version of this sensor, the visual indicator is apivotable flap having different colours on opposite sides of the flapand the release mechanism is a straight metal wire or metal spring, oneend of which is connected to the flap and the other end of which isconnected to the support means.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of a present fluid condition sensor willbecome apparent from the following detailed description taken inconjunction with the accompanying drawings which illustrate variouspreferred embodiments, in which:

FIG. 1 is schematic view of a radiator and overflow reservoir for avehicle cooling system employing the present invention;

FIG. 2 is a schematic view of a vehicle cooling system wherein thepresent invention is installed at an alternate location in the system;

FIG. 3 is a top view of a first version of the invention arranged in atubular hose fitting;

FIG. 4 is an axial cross-sectional view taken along the line IV--IV ofFIG. 3;

FIG. 5 is a transverse cross-sectional view taken along the line V--V ofFIG. 6 of another embodiment of the invention, again arranged in atubular hose fitting;

FIG. 6 is a side view of a tubular pipe fitting incorporating oneversion of the invention;

FIG. 7 is a side view of a further version of the invention arranged ina tubular pipe fitting;

FIG. 8 is an axial cross-section of the version of FIG. 7 taken alongthe line VIII--VIII of FIG. 7;

FIG. 9 is an axial cross-section of another embodiment of the inventionarranged in a tubular pipe fitting;

FIG. 10 is a detailed view in cross-section of an embodiment of theinvention similar to that shown in FIG. 9, this view omitting thetubular pipe fitting;

FIG. 11 is an end view of the shaped cathode shown in FIG. 10;

FIG. 12 is a detailed cross-section of a further version of theinvention employing a flat anode member and a cathode with externalthreading for attaching the unit in a pipe fitting;

FIG. 13 is a schematic view of a corner of a vehicle radiator showingthe location of another version of the invention;

FIG. 14 is a cross-sectional view taken along the line XIV--XIV of FIG.13;

FIG. 15 is a cross-sectional detail similar to that of FIG. 14 butshowing still another embodiment of the invention employing a movableindicator; and

FIG. 16 is a front view of the embodiment of FIG. 15.

FIG. 17 is a cross-sectional view similar to FIG. 14 but showing afurther version of the invention;

FIG. 18 is a cross-sectional view of the indicator ball used in theembodiment of FIG. 17;

FIG. 19 is a cross-sectional detail of a preferred version of a sightglass usable in the embodiment of FIG. 14;

FIG. 20 is a side view of a further embodiment which combines acorrosion sensor with a specific gravity indicator; and

FIG. 21 is a transverse cross-section taken along the line XXI--XXI ofFIG. 20.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a portion of a cooling system for an automotivevehicle including a radiator 10 (which is a form of heat exchanger)having an inlet 11 for hot coolant from the vehicle engine jacket and anoutlet 12 leading to a coolant pump for the engine. The top of theradiator is a pressure relief vent cap 14 on a filler neck 13. This neckis located at the top of an inlet tank 15 for the radiator. An overflowline 16 leads from the vent cap to an overflow reservoir 17 for thecoolant.

Interposed in the overflow conduit 16 is a fluid condition sensor 20,the details of which are explained hereinafter. This sensor 20 isprovided to enable the user of the vehicle or a mechanic responsible forthe maintenance of same a visual indication through a sight glass orwindow of the sensor as to whether the heat exchanging fluid in thesystem has reached a certain corrosive state. An indication can beprovided by the viewing of a flap or ball through the window, the flapor ball displaying a colour indicating the need for a change of the heatexchanging fluid or, alternatively, the need for the addition ofcorrosion inhibitors. The indication of a corrosive state can also beprovided simply by the presence of heat exchanging fluid on the insidesurface of the window or sight glass where it can be clearly seen.

In a preferred version of the invention, the sensor is constructed sothat the visual indicator will be triggered or present before the heatexchange fluid becomes so corrosive that it can cause significant damageto the radiator or heat exchange system. Thus, the user of the vehicleor the mechanic is advised by the indicator to change or treat the heatexchange fluid before considerable damage to the radiator or other majorcomponents of the system is caused.

FIG. 2 illustrates an alternate arrangement for installing a fluidcondition sensor constructed in accordance with the invention in avehicle cooling system indicated generally at 25. This system includesan engine 26 or other heat source having a cooling jacket, a hot fluidconduit 27 from the engine to the inlet tank 29 of a radiator 28, and acooled fluid conduit 30 from the outlet tank 31 leading to fluid pump 34operated by the engine to pump the coolant through a conduit 35 to thecooling jacket. A filler neck 36 on inlet tank 39 has a pressure reliefcap 38 and an overflow conduit 40 leads from the neck to an overflowreservoir 41. A corrosion sensor 20 constructed in accordance with theinvention is positioned in the conduit 27 and is in the form of atubular pipe fitting that can be readily attached in a break provided inthe conduit 27.

A first version of a fluid condition sensor 20 constructed in accordancewith the invention is illustrated in detail in FIGS. 3 and 4. The sensorincludes support means 45 for mounting the sensor in the heat exchangeror radiator system in such a manner that heat exchanging fluidcirculated in the system comes into contact with the sensor. The supportmeans shown in FIGS. 3 and 4 is in the form of a tubular hose fittinghaving an inlet 46 at one end and an outlet 48 for the heat exchangingfluid at the other end. Annular ridges 49 and 50 can be provided on theexterior of a fitting to assist in the attachment of a hose. The fittingwhich is in the form of a T has a cylindrical extension 52 on one sidelocated midway along the length of the fitting. Mounted in thisextension is a sight glass means or window 54 which is transparent ortranslucent so that one looking through the sight glass can viewmaterial, shapes or colours therethrough. The term "sight glass means"as used herein includes not only a small window or viewing piece made ofglass but also other suitable transparent or translucent material suchas clear plastics that are able to withstand the temperatures at whichthe heat exchanger or radiator operates. The sight glass can be mountedsecurely in place by known mechanical means such as crimping, clampingor screwing. Alternatively it can secured by a suitable adhesive.

The sensor also has corrodible separating means 58 interposed betweenthe sight glass 54 and the heat exchanging fluid passing through thefitting. In the embodiment of FIGS. 3 and 4, the separating meanscomprises a metal diaphragm mounted in the extension 52 and spaced fromthe sight glass so that there is a normally empty chamber 60 arrangedbetween the diaphragm and the sight glass. A variety of corrodiblematerials can be used for the diaphragm including aluminum and magnesiumalloys.

A visual indication of the corrosive state of the heat exchanging fluidis provided by the sensor 20 when the separating means 58 is ruptured orbroken by corrosion caused by the corrosive state of the heat exchangingfluid. It will be appreciated that when the diaphragm does rupture, theheat exchanging fluid will enter the chamber 60 where it can be viewedthrough the sight glass. The presence of the heat exchanging fluid belowor next to the sight glass indicates to the user of a vehicle that theheat exchanging fluid or coolant must either be replaced or treated withinhibitors so that the corrosiveness of the fluid is reduced to safelimits. If desired, a small pellet or wafer of dye or dye containingmaterial can be inserted in the chamber 60. This will cause the colourof the fluid entering the chamber to change to a clearly visible colour(for example red). In the alternative, the wafer itself can be made tochange colour in the presence of the fluid in order to indicate theonset of corrosive conditions.

As discussed in more detail hereinafter, tests have shown that selectedor candidate corrodible materials perforate much faster than standardradiator materials in the same corrosive environment. Thus the abilityfor a corrodible diaphragm to be broken or perforated at an early stageto provide the required indication of a corrosive condition prior todamage to the cooling system is demonstrated in test results. Inaddition, these tests indicate that these corrodible materials used forthe diaphragm do not corrode or perforate in a fully inhibited coolant.Therefore a corrosive condition should not be indicated prematurely bythe present sensors as described herein.

The diaphragm can be secured in place in a pipe fitting in a variety ofways including known mechanical methods such as crimping, clamping, andscrewing and including magneforming. Welding brazing or soldering arefurther possible methods of attachment. Adhesive bonding can be used butif galvanic contact is required, the adhesive must be conductive.

Turning now to the embodiment shown in FIGS. 5 and 6 of the drawings,this sensor 62 is also in the form of a tubular pipe fitting with acylindrical extension 64. As in the embodiment of FIG. 4, there is asight glass or window 66 mounted near the outer end of the extension andspaced below this window is a corrodible metal diaphragm 68. However, inthis embodiment the diaphragm is mounted in a metal tubular member 70,the top portion of which is located in the extension 64 and a bottomportion of which extends into a main passageway 72 of the tubularfitting. In order to cause the diaphragm 68 to corrode quickly when theheat exchanging fluid reaches a corrosive state, the diaphragm 68 andthe member 70 are constructed and arranged to form a galvanic couplewith the diaphragm being the anode and the tubular member 70 being thecathode. Both the anode and cathode are exposed to the coolant that isflowing through the passageway 72. The diaphragm 68 must be mounted sothat it is in mechanical contact with the member 70. The diaphragm canbe mounted by magneforming or mechanical assembly.

In order to prevent air from being trapped in the member 70 below thediaphragm 68, there is a hole 74 provided in the member 70 near theanode. The cathode 70 is made from a more noble metal than the metalforming the diaphragm 68. A preferred metal for the cathode is copper.Preferred materials for the anode are aluminum and magnesium alloys. Therelevant surface areas of cathode and anode that are exposed to thecoolant, as well as the selection of the anode and cathode materials arecontrolled by design factors to adjust the sensitivity of the couple tocoolant corrosivity. The amount of the cathode exposed to the coolantshould be relatively large as in the embodiment of FIGS. 5 and 6. Alarge cathode will provide a relatively large cathode:anode surface arearatio, thus ensuring an adequately large galvanic driving force so thatthere is a desirable sensitivity to coolant condition.

The embodiment of FIGS. 5 and 6 has a second visual indicator providedon the tubular fitting, the purpose of which is to indicate to the useror to the mechanic the density of the heat exchange fluid or coolant andthe extent to which this fluid provides safe freeze point protection.The second visual indicator 80 is in the form of at least one colouredball 82 and a transparent tube 84 for holding the ball or balls in heatexchanging fluid contained in the tube. The ball or balls are free tomove to limited extent in the fluid, the amount of movement beinglimited by the internal dimensions of the tube 84. As shown this tubehas a bottom end 86 and an upper end 88 located in the region of theextension 64. The flotation of one or more balls or the lack thereofindicates the density of the heat exchanging fluid or coolant which inturn indicates the extent to which the fluid provides safe freeze pointprotection.

In order to permit the circulation of heat exchanging fluid in the tube80, two holes 90 and 92 extend between this tube and the interior of thetubular hose fitting and are positioned near opposite ends of the tube.Because the coolant is able to circulate in the tube 80, the fluid inthe tube accurately and continuously represents the condition of thecoolant in the system Although the tube could extend perpendicularly tothe central longitudinal axis of the fitting, preferably the tube 80mounted on the exterior of the hose fitting extends at an acute angle tothe central longitudinal axis as shown clearly in FIG. 6. By arrangingthe tube in this manner, the balls in the tube and the tube itself arevisible from different angles and view points so that they can be seenwithout undue difficulty.

In the case of an indicator containing a number of balls 82, the ballswill vary in density so as to provide a clear indication of the densityof the fluid. For example, if only two balls are floating in the tube,that is it has risen to the top of the tube, and a third ball has sunk,this can indicate to the user that the fluid is slightly less dense thanit would be if the fluid was in its ideal state (for example, that thepercentage to water in the fluid exceeds 50%). If two balls have sunk inthe tube, this indicates that the fluid is even less dense and perhapsis in need of further ethylene glycol solution. The sinking of all ofthe balls in the tube will indicate to the user that the heat exchangefluid is definitely to weak in strength and the percentage of water inthe system must be reduced, possibly by the replacement of all of theheat exchanging fluid or coolant.

If only one coloured ball 82 is used in the tube 80, the amount by whichthe ball sinks in the tube 80 will provide the indication of fluiddensity. For this purpose, a scale or series of marks 100 can beprovided on the tube. Numerical indicia (not shown) can also be providedon the tube to indicate to the user or mechanic the density of the fluidin the system or perhaps the safe freeze point provided by the fluid.

Preferably, the sensor of FIGS. 5 and 6 is installed in the upper hoseof a radiator so that it will be readily visible when the hood of thecar is raised. The engine of a car should be shut-off when one is goingto obtain a reading of fluid density by viewing the tube 80 and theballs therein. Otherwise the flow of coolant through the system maycause the balls to move in the tube simply due to the fluid flow and notdue to the density of the fluid. The sensor 62 should be installed inthe system so that the fluid flow is in the direction indicated by thearrow A in FIG. 6. This will cause the fluid to flow into the hole 90through the tube 80 and out through the hole 92. With the flow in thisdirection, the balls in the tube should not unduly interfere with theflow of fluid through the tube.

If a number of balls 82 are used in the sensor of FIGS. 5 and 6, theballs can have different colours to indicate densities. Also, if visiblemarks are required on the tube 80, these can be provided by printedsticker attached to the tube. Also the marks can be silk-screened on thesurface of the tube.

Turning now to the embodiment illustrated by FIG. 7 and 8, this sensor102 is also in the form of a tubular fitting suitable for installationin the hose of a radiator system. The sensor 102 has a sight glass orwindow 104 mounted in the side thereof, preferably midway along thelength of the fitting as shown. On the inside surface of this window isa corrodible opaque coating 106 covering the entire window. Preferablythe coating is made of anodic material. This coating is no shown in FIG.7 which shows the window 104 in its transparent form after the coating106 has been corroded away. The coating 106 is of course located so thatheat exchanging fluid passing through the passageway 108 of the fittingcontacts the coating during use of the sensor. The coating can betotally adhered to the window or just at its periphery. A visualindicating means, which in this case is a coloured ball 110 can beviewed through the sight glass 104 when the opaque coating 106 is atleast partially removed by corrosion. The greater degree of corrosion ofcourse, the more the ball is visible. Instead of the ball 110, acoloured vane or a device like a thick fan blade could be used as theindicator. Also several small coloured balls can be used instead of asingle ball provided their movement in the fitting is suitablyrestrained.

The sensor 102 includes means for restraining movement of the ball 110in the sensor so that the ball will not flow out of the sensor and intothe heat exchanger system. In the illustrated version the restrainingmeans comprises two spaced-apart restrictions 112 and 114 arranged inthe passageway 108, the ball 110 being located between theserestrictions. The diameter D of a hole formed by each restriction isless than the diameter of the ball 110 so that the ball cannot pass bythe restriction. The restriction should keep the ball in the vicinity ofthe sight glass so that the ball can be seen once the coating iscorroded away. Preferably the ball is brightly coloured so that it canbe seen even in poorer light conditions. If desired, two windows orsight glasses 104 can be provided in the sensor 102, these being locatedon opposite sides of the fitting.

Still another version of the invention is illustrated by FIGS. 9 to 11wherein the sensor is indicated generally by reference 120. The sensor120 has a support means in the form of a tubular hose fitting 122 with afluid passage 124 extending thereto. A cylindrical extension 126 of thefitting projects from one side thereof. An opening 128 in the side ofthe main passageway permits coolant to flow into the extension where itcontacts a metal diaphragm 130. Preferably this diaphragm is selectedand constructed so as to corrode and rupture before the heat exchangefluid or coolant becomes so corrosive that it can cause significantdamage to the system. A rupture of the diaphragm causes the heatexchanging fluid to flow into a normally empty chamber 132. This chamberis formed on one side by a window element or sight glass means 134. Inthis version the sight glass is in the form of an inverted cup with anannular flange 135 at the bottom. Located on top of this flange is asuitable seal or rubber gasket 136 which effectively prevents the escapeof heat exchanging fluid through the opening 128.

A galvanic couple is formed in the version of FIG. 9 by the corrodibleanode partition or diaphragm 130 and a contacting cathode/container 140which includes a cylindrical bottom extension and a threaded upperportion 142. The cathode/container 140 is made of a noble metal such ascopper or possibly titanium. The upper portion threads into the fittingextension 126. The anode partition 130 rests on annular shoulder formedin the cathode/container 140. The cathode/container has an inwardlyextending annular lip 144 which engages the top of the seal 136. Thecathode/container can be formed around the diaphragm 130 and the flange135 by known methods such as cold clinching, rolling, or magnaforming.It is also possible to secure the diaphragm to the flange 135 byadhesive, thereby helping to seal the chamber 132. If desired, therubber gasket 136 can extend around the edge of the flange 135 and theedge of the anode.

The version of the sensor shown in FIG. 10 is similar to that of FIG. 9except that there is a separate, shaped cathode 146, a bottom end viewof which is shown in FIG. 11. The cathode 136 has an outwardly extendingflange 148 and the anode 130 rests on top of the cathode. There is aseparate, generally cylindrical container 150 which is externallythreaded at 152. An annular bottom flange 154 of the container engagesthe flange of the cathode in order to support same.

The cathode 146 has a shaped passageway 156 extending therethrough. Inthe illustrated version, the passageway 156 is star-shaped incross-section, thus presenting a large surface area to the heatexchanging fluid or coolant. The version of FIGS. 10 and 11 has theadvantage of providing a relatively large cathode:anode surface arearatio. Because of this a large galvanic driving force is provided andthis gives the device the required sensitivity. The preferred materialfor the more noble metal of the cathode is copper or titanium.

According to the aforementioned published paper entitled "ControlledRelease of Inhibitors for Extended Protection of Aluminum in EngineCooling Systems" by Brian Cheadle et al. a representative aluminum alloynamely AA7072, that is locally thinned and galvanically coupled to thenoble metal titanium will corrode at lower levels of coolant depletionthan a representative aluminum alloy used in radiators, namely type3003. Furthermore cast aluminum corrosion tests in simulated depletedcoolants have indicated that relatively high degrees of coolantdepletion are required to initiate corrosion damage in aluminum cylinderhead material compared to corrodible diaphragm material.

Generally speaking the cathode materials used herein can be any metal ormaterial (i.e. graphite) that is cathodic to the anode provided (that isthere should be a large difference in the galvanic series) and that isunlikely to polarize or passivate in service.

Another version of the invention which uses a combined cathode/containerin which the anode partition is mounted is shown in FIG. 12. It will beunderstood that this sensing device 160 as illustrated is designed to bethreaded into a tubular hose fitting of a type shown in FIG. 9. For thisreason, it has external threads 162 provided on a cathode/container 164.An anode partition 166 rests on a shoulder 168 formed by thecathode/container. Located directly on top of the anode 166 is asubstantially flat sight glass or window 170. A seal or rubber gasket172 is arranged around the circumference of the sight glass which isheld in place by an upper, inwardly extending flange 174.

Again, if desired, the gasket 172 can be C-shaped in cross-section andcan extend around the edge of the sight glass and the edge of the anode.

Sandwiched between the anode 166 and the sight glass 170 is a layer ofcolour changing dye 176 or a wafer of same. If desired the sight glass170 can have a shallow recess 178 in a central portion thereof toaccommodate this dye material. It will be understood that upon ruptureof the anode 166 the liquid coolant will contact the dye materialcausing it to change colour, for example to the colour red. This willindicate to the user of the vehicle or the mechanic that it is time tochange or treat the coolant.

Still another version of the invention is shown in FIGS. 13 and 14. Inthis version the sensor 180 is shown installed in the side of a radiatortank 182, only a lower portion of which is shown in FIG. 13. Thepossible location of this sensor 180 is also shown in dashed lines inFIG. 1 which illustrates a complete radiator. The metal sidewall 184 ofthe tank is provided with a hole 186 where the sensor is to be located.The coolant or heat exchanging fluid circulates by this hole asindicated by the arrow at 188. In this version the wall of the tankforms part of a support means for mounting the sensor. A sight glass 190is mounted on the outside of the tank wall by connecting tabs 192. Thesight glass in this version comprises a glass dome with a hemisphericaltop. Formed inside this dome is a fluid chamber 194. Visual indicatingmeans are provided in this fluid chamber and these comprise a singlecoloured ball 196. The glass dome has a restricted throat 198 having awidth X. It will be understood that the diameter of the ball 196 exceedsthe distance X so as to provide means for restraining movement of theball in the sensor. Thus the ball cannot escape from the sensor 180 intothe tank 182.

A corrodible opaque coating 200 selected from an anodic material such asaluminum, zinc or magnesium is provided on the inner surface of thesight glass and is located so that heat exchange fluid or coolantcontacts the coating during use of the sensor. The coatings may be aspure metals, or as alloys, for instance aluminum and magnesium alloys.The coatings may be deposited by electroless or electrolytic plating, orby vacuum deposition (for example evaporative coating, sputtering, etc.)or chemical deposition methods. As this opaque coating is corroded awayby the coolant (when it reaches a corrosive state) the ball 196 willbecome visible, thereby indicating a need to replace or treat thecoolant.

Another sensor 210 employing a glass dome 212 is shown in FIGS. 15 and16. The illustrated support means for mounting the sensor is a wall 214of a radiator tank. Thus coolant circulates by the sensor 210 asindicated by the arrow 216. A visual indicator 218 is mounted on theside of the tank and is movable from a first position shown in solidlines in FIG. 15 indicating that the heat exchange fluid is in anon-corrosive state to a second position shown in dashed lines(indicated by reference 220) indicating that the fluid has becomecorrosive to at least a limited degree. In the illustrated embodimentthe indicator is a pivotable flap having different colours on oppositesides of the flap. For example, on the visible side 222 of a flap as itis shown in FIG. 15 there can be the colour green while on the oppositeside 224 the flap can be red. It will be appreciated that when the flapmoves to the position 220, the red colour will be visible. The sensor210 has a corrodible release mechanism 226 for holding the indicator inthe first position and located so as to be immersed in the heat exchangefluid or coolant during use of the sensor. In the illustrated versionthe release mechanism is preferably a corrodible metal wire or thinstrip between approximately 0.010 inch and 0.050 inch in thickness ordiameter, one end of which is connected to the flap and the other end ofwhich is connected to the sensor support, in this case the wall of thetank.

The corrodible material is preferably selected from an anodic metal suchas aluminum, zinc or magnesium. Testing has been conducted primarily onaluminum, aluminum-zinc alloys, and magnesium alloys. Examples of suchalloys are AA7072 aluminum-zinc and MIX or AZ31 magnesium alloys. Thecorrosion rate of these materials is adjusted by the alloy content,thickness or galvanic coupling. Preferred materials for the wire orstrip are AA7072, A231 or MIX magnesium. Wire thicknesses of less than0.010 inch are feasible but are increasingly subject to metaldegradation or handling damage during manufacture as the thickness isreduced. Wire thicknesses from 0.050 inch to about 0.125 inch are alsopossible and can be made to corrode in relatively short times. However,it becomes more difficult to ensure a penetration or separation of thecorrodible material at thicknesses much above 0.10 inch. Instead of awire or strip configuration, a metal spring connector can be used.

A preferred form of corrosion rate adjustment is the galvanic couplingto a noble metal such as copper and titanium and this can be used in theembodiment of FIGS. 15 and 16. In such a case the wire 226 can form theanode while either the indicator 218 or the material at 230 to which oneend of the wire is connected can form the cathode and be made of acathodic material. The thus formed galvanic couple provides means forcontrolling the corrosion of the spring.

In this version and in the earlier versions employing a corrodiblediaphragm or corrodible coating, a galvanic coupling can be provided bycoating or cladding corrodible material with a noble material. In thisvariation the noble material is locally removed to expose an anodic areafor preferential corrosion attack.

Two holes are provided in the side of the tank to permit the circulationof fluid through a chamber 232 formed by the glass dome. These holes 234and 236 are preferably located on opposite sides of the hinge axis ofthe indicator 218. When the release mechanism 226 breaks, the heatexchanging fluid flow in the chamber causes the indicator or flap tomove to the second position at 220. An annular seal or sealant isprovided at 240 to prevent leakage of coolant at this location. Ifdesired a flow diverter 242 can be provided on the inside of the tankwall to encourage or divert the flow of coolant through the chamber 232.

A series of "perforation time" corrosion tests of candidate corrodiblediaphragm materials (magnesium and aluminum) have been carried out toassess the operation of the sensors described herein. The results ofthese tests are set out in Table I on the accompanying page. These testswere in the nature of "glassware" corrosion testing (ASTM D1384)measuring time to perforation in corrosive water, depleted coolant andfully inhibited coolants. The magnesium alloy tested was M1X. Aluminumalloys 3003 and 1145 are considered representative of aluminum radiatormaterials and these also were tested. In these tests these two aluminumalloys were locally thinned to make a "worst case" comparison tocandidate corrodible materials. The tests indicate that candidatecorrodible materials perforate much faster than radiator materials inthe same corrosive environment. Thus these tests indicate that thepresent sensors employing suitable corrodible materials do have theability to indicate a corrosive condition in the cooling system prior todamage to the system. The tests further indicate that these corrodiblematerials do not corrode or perforate in a fully inhibited coolant seethe last column in the Table) and therefore a corrosive condition willnot be indicated prematurely by the sensors described herein.

                                      TABLE I                                     __________________________________________________________________________    GLASSWARE CORROSION TESTING                                                   (ASTM D1384 METHOD, CYCLIC HEATING TO 88° C., 8 HRS. ON/16 HRS.        OFF                                                                                        PERFORATION TIME (DAYS)                                                       330 ppm Cl.sup.-  +                                                                    ASTM    1/4 Rec. Dose*                                               1 ppm Cu.sup.+                                                                         Corr.                                                                             Tap (12.5%) PII Balance                                                                     50% PII                                            Corr. water                                                                            Water                                                                             Water                                                                             ASTM Corr. Water                                                                        Balance tap water                     ALLOY                                                                               CONDITION                                                                             ##STR1##                  (Fully  Inhibited)                    __________________________________________________________________________    Mix Mg                                                                             .050" thick                                                                           --       --  --  6          >40                                  (1% Mn,                                                                            galvanically                                                             Bal. Mg)                                                                           coupled to Cu                                                            AA 7072                                                                            .010" thick                                                                            <1      1     2 8         >120                                       coined to .0016"                                                              coupled to Ti                                                            AA 7072                                                                            .010" thick                                                                             3      --  --  --        --                                         coined to .0016"                                                              no couple                                                                AA 2024                                                                            .004" thick                                                                             5      --  >30 --        >120                                       no coin                                                                       no couple                                                                AA 3003                                                                            .010" thick                                                                           >19      --  --  --        >120                                       coined to .004"                                                                       (Pitting corrosion                                                    no couple                                                                             initiated Day 16)                                                AA 1145                                                                            .010" thick                                                                           >22      --  --  --        >120                                       coined to .004"                                                               no couple                                                                __________________________________________________________________________     *Note: PII = Prestone II antifreeze. A 50% concentration in tap water is      recommended as a fully protective "dose". A 12.5% concentration is thus a     "1/2 dose"; this low concentration in ASTM corr. water is considered          moderately corrosive, and representative of a depleted coolant condition.

The corrosion sensor of FIGS. 15 and 16 can be combined of course with asecond fluid condition sensor similar to that used in the version ofFIGS. 5 and 6, the second sensor providing an indication of the specificgravity of the fluid and thus solution strength. In such a combination,the flow of fluid out through the passageway 236 can be directed to atube or channel containing one or more balls visible from the outside.It will be further appreciated that the version of FIGS. 15 and 16 neednot necessarily be mounted in a radiator tank wall and this version canalso be mounted in a tubular hose fitting, if desired.

FIG. 17 illustrates a further embodiment of the invention which issimilar in its appearance to that of FIGS. 13 and 14. However in thisversion the sensor 250 has a sight glass 252 with no corrodible opaquecoating thereon. In other words, the sight glass is clear or transparentat all times. The sight glass is mounted to the side of the tank bymeans of connecting tabs 192 in the same manner as the version of FIG.14. Inside the dome of the sight glass is a fluid chamber 254. Again avisual indicator is provided in the fluid chamber in the form of asingle coloured ball 256. The ball is restrained from exiting the glassdome by means of restricted throat 198.

In this version the ball 256 has a corrodible coating 260 extending overits entire surface. Because of the circulation of the heat exchangingfluid in the chamber, this fluid contacts the coating during use of thesensor. When the coating is at least partially removed by corrosioncaused by the heat exchanging fluid, the ball changes colour as thecolour of the coating differs from the colour of the ball on its surface262.

A preferred version of the ball 256 has an inner or first layercomprising a suitable water soluble material such as water solublepolymer. This inner layer 264 is covered completely with the coating 260so that the heat exchanging fluid does not initially come into contactwith this layer. The purpose of the layer 262 is to provide a "lift-off"of the opaque coating 260 once the initial penetration of the coatinghas occurred. In this way the entire surface of the ball is quicklycleared of the coating 260 once a corrosive condition in the coolantoccurs. Possible water soluble polymers include polyvinyl alcohol,polyoxyethylene or others described in U.S. Pat. No. 4,333,850.

The preferred form of coating for the ball 256 comprises a first layer266 of anodic corrodible material such as aluminum, zinc or magnesium.These may be pure metals, or alloys. The coating 260 also includes afurther or second layer of cathode material at 268 which extends over asubstantial portion of the exterior of the anodic material. However, thecathode layer 268 is locally masked or removed at 270 to expose theanodic layer. It will be appreciated that in this way a galvanic coupleis provided. The coatings on the ball may be deposited by electroless orelectrolytic plating, by vacuum deposition, or chemical vapourdeposition methods.

FIG. 19 is a detailed view illustrating a preferred version of the sightglass used in the embodiment of FIGS. 13 and 14. In this version thesight glass 190 has on the inside of the glass dome an inner layer 272comprising a suitable water soluble material such as water solublepolymer. The corrodible opaque coating 200 extends over the entire innerlayer so as to prevent the heat exchanging fluid from initiallycontacting the layer 272. As in the ball 256 of FIG. 18 the inner layer272 is designed to "lift-off" the opaque coating 200 once an initialcoating perforation has occurred. In this way the entire inner surfaceof a sight glass becomes clear quite quickly once a corrosive conditionin the coolant occurs. A preferred form of coating 200 includes a firstlayer of anodic corrodible material 274 and a second layer of cathodematerial 276 extending over a substantial portion of the exterior of thelayer 274. However again the cathode layer is locally masked or removedat 278 to expose the anodic layer. The coating 200 can be deposited inthe same manner as the coating on the ball 256.

Turning now to the embodiment illustrated in FIGS. 20 and 21 of thedrawings, this embodiment constitutes a combination corrosion sensor andspecific gravity indicator indicated generally by 280. As in theembodiment of FIG. 6, this sensor is illustrated in the form of atubular pipe fitting but in this version there is no sight glass in thesense of the present application and there is no corrodible diaphragm.There is a visual indicator which includes one or more coloured balls282 (three being shown in the drawings) and a transparent tube 284 forholding the ball or balls in heat exchanging fluid contained in thetube. The ball or balls are free to move to a limited extent in thefluid. The tube has a bottom end 286 and an upper end 288. As in theearlier version, the flotation of one or more balls 282 or the lackthereof indicates the specific gravity of the heat exchanging fluid orcoolant which in turn indicates the extent to which the fluid providessafe freeze point protection.

In order to permit the circulation of heat exchanging fluid in the tube,two holes 290 and 292 extend between the tube and the interior of thetubular hose fitting. In this embodiment the ball or balls have acorrodible opaque coating 294 thereon, this coating being constructed inthe same manner as that on the ball 256 of FIG. 18. Thus the balls areadapted to change their colour when the coating is at least partiallyremoved by corrosion caused by the heat exchanging fluid. It will thusbe appreciated that the sensor 280 of FIGS. 20 and 21 provides a dualpurpose sensor which is quite simple in its construction.

In those preferred embodiments of the invention employing a metaldiaphragm or partition, it is preferable for the metal used to be anodici.e. aluminum, zinc, or magnesium. It is strongly preferred that theanodic material be coupled to a more noble metal, although the corrosionrate (time) of the corrodible metal can also be adjusted by thinning orforming.

Various methods have been mentioned for securing the diaphragm in placein the fitting. A further method that can be used in the case of acorrodible diaphragm that is coated with the cathodic material is simpleinjection moulding, the plastic housing being forced around thediaphragm which is secured at the correct location.

It will be clear to those skilled in the construction of radiator andheat exchange systems that various modifications and changes can be madeto the described embodiments without departing from the spirit and scopeof this invention. Accordingly, all such modifications and changes thatfall within the scope of the appended claims are intended to be part ofthis invention.

What is claimed is:
 1. A fluid condition sensor for a heat exchangersystem, comprising:support means for mounting the sensor in said systemin such a manner that heat exchanging liquid circulated in said systemcomes into contact with said sensor; sight glass means mounted in saidsupport means; corrodible separating means mounted in said support meansin such a way that said separating means is interposed between saidsight glass means and a portion of said system through which said heatexchanging liquid is circulated so that when heat exchanging liquid ispresent in said system said heat exchanging liquid contacts saidseparating means, said separating means being perforated, ruptured orbroken by corrosion from said heat exchanging liquid when said heatexchanging liquid reaches a predetermined corrosive state; and visualindicating means which can be viewed through said sight glass means whensaid separating means is perforated, ruptured, or broken by saidcorrosion, the viewing of same providing an indication that said heatexchanging liquid has reached a predetermined corrosive state.
 2. Afluid condition sensor according to claim 1 wherein said separatingmeans is a metal diaphragm mounted in said support means, the type ofmetal and thickness thereof being such that when the heat exchangerliquid reaches a predetermined corrosive state, said diaphragm iscorroded, perforated or ruptured right through at a much greater ratethan that at which the other metal components of the system corrode. 3.A fluid condition sensor according to claim 1 wherein said indicatingmeans is at least one coloured movable object and means for holding saidat least one movable object in the heat exchanging liquid of said systemso that said at least one movable object is free to move to a limitedextent in said heat exchanging liquid.
 4. A fluid condition sensoraccording to claim 1 wherein said support means is a tubular hosefitting having an inlet and an outlet for said heat exchanging liquid.5. A fluid condition sensor according to claim 1 wherein said separatingmeans is an opaque corrodible coating on an inner surface of said sightglass means.
 6. A fluid condition sensor according to claim 1 includinga number of coloured balls and a tube for holding said balls in the heatexchanging liquid of said system so that said balls are free to move toa limited extent in said heat exchanging liquid and wherein said ballsvary in density so that the number of balls floating or sinking in saidheat exchanging liquid is an indication of the density of the fluid andthe extent to which the liquid provides safe free point protection.
 7. Afluid condition sensor according to claim 6 wherein said support meansis a tubular hose fitting having a central longitudinal axis and aninlet and an outlet for said heat exchanging liquid, said tube for saidballs being mounted on the exterior of said hose fitting and extendingat an acute angle to said longitudinal axis.
 8. A fluid condition sensoraccording to claim 6 wherein said separating means is a metal diaphragmspaced from said sight glass means.
 9. A fluid condition sensoraccording to claim 1 including further visual indicating means in theform of a transparent tube containing one or more balls, said tubecontaining some of said heat exchanging liquid during use of saidsensor, wherein the flotation of said one or more balls in said tubeindicates the extent to which the liquid provides safe freeze pointprotection.
 10. A fluid condition sensor according to claim 1 whereinsaid visual indicating means is provided by the heat exchanger liquid.11. A fluid condition sensor according to claim 1 wherein saidseparating means is spaced from said sight glass means so that a chamberis located between said separating means and said sight glass means,said chamber containing a quantity of material that changes color uponcontact with the heat exchanging liquid thereby forming said visualindicating means.
 12. A fluid condition sensor according to claim 1wherein said separating means is spaced from said sight glass means sothat a chamber is located between said separating means and said sightglass means, said chamber containing a quantity of material which causesa color change in said liquid when said liquid enters said chamberthereby forming said visual indicating means.
 13. A fluid conditionsensor according to claim 1 wherein the separating means is a metaldiaphragm fabricated from a metal selected from the class comprisingaluminum, zinc, magnesium and alloys thereof.
 14. A corrosion sensor fora heat exchanger system, comprising:support means for mounting thesensor in said system to enable the sensor to contact heat exchangingliquid flowing through the system; a corrodible diaphragm mounted insaid support means where said liquid can contact one side of saiddiaphragm when said corrosion sensor is mounted in said system havingheat exchanging liquid located therein, said diaphragm being selectedand constructed so as to rupture from corrosion from said heatexchanging liquid when said liquid reaches a predetermined corrosionstate; and sight glass means mounted in said support means on the otherside of said diaphragm, a normally empty chamber located between saiddiaphragm and said sight glass means; wherein said diaphragm rupturesfrom corrosion before said heat exchanging liquid becomes so corrosivethat it can cause significant damage to said heat exchange system, arupture of said diaphragm causing said liquid to flow into said chamberand thereby indicating a need to change or treat said heat exchangingliquid.
 15. A corrosion sensor according to claim 14 wherein saidsupport means is a tubular hose fitting having an inlet and an outletfor said heat exchanging liquid and an opening in one side thereof inwhich said diaphragm and said sight glass means are mounted.
 16. Acorrosion sensor according to claim 15 wherein said opening in one sideof the fitting is threaded to receive an externally threaded metal ringin which is arranged both said diaphragm and said sight glass means. 17.A corrosion sensor according to claim 16 wherein said diaphragm is madeof one corrodible metal and said ring is made of a different more noblemetal and the diaphragm and ring form respectively an anode and acathode of a galvanic couple.
 18. A corrosion sensor according to claim14 wherein said chamber contains a quantity of material that changescolour upon contact with the heat exchanging liquid.
 19. A corrosionsensor according to claim 16 wherein said chamber contains a quantity ofmaterial that changes colour upon contact with the heat exchangingliquid.
 20. A corrosion sensor according to claim 14 including visualindicating means in the form of at least one coloured ball and atransparent tube for holding same in said heat exchanging liquid so thatsaid at least one ball is free to move to a limited extent in saidliquid, the flotation of one or more balls or lack thereof indicatingthe specific gravity of said heat exchanging liquid and the extent towhich the liquid provides safe freeze point protection.
 21. A corrosionsensor according to claim 16 including visual indicating means in theform of a number of coloured balls and a transparent tube for holdingsame in said heat exchanging liquid so that said balls are free to moveto a limited extent in said liquid, the flotation of one or more ballsor the lack thereof indicating the specific gravity of said heatexchanging liquid and the extent to which the liquid provides safefreeze point protection.
 22. A corrosion sensor according to claim 16including visual indicating means in the form of a number of colouredballs and a transparent tube for holding same in said heat exchangingliquid so that said balls are free to move to a limited extent in saidliquid, two holes extending between said tube and the interior of saidtubular hose fitting and positioned near opposite ends of said tube forthe balls in order to permit the heat exchanging liquid to flow into andthrough said tube for the balls, the flotation of one or more balls orthe lack thereof indicating the specific gravity of said heat exchangingliquid and the extent to which the liquid provides safe freeze pointprotection.
 23. A corrosion sensor for a heat exchange systemcomprising:support means for mounting the sensor in said system toenable the sensor to contact heat exchanging fluid flowing through thesystem; sight glass means mounted in said support means; a corrodibleopaque coating on an inner surface of said sight glass means and locatedso that said heat exchanging fluid contacts said coating during use ofsaid sensor; and visual indicating means which can be viewed throughsaid sight glass means when said opaque coating is at least partiallyremoved by corrosion caused by said heat exchanging fluid.
 24. Acorrosion sensor according to claim 23 wherein said visual indicatingmeans is a coloured movable object, said sensor including means forrestraining movement of said movable object in said sensor.
 25. Acorrosion sensor according to claim 24 wherein said support means is atubular hose fitting having an inlet and an outlet and an opening in oneside thereof in which said sight glass means is mounted.
 26. A corrosionsensor according to claim 25 wherein said fitting has a fluid passagewayextending between said inlet and said outlet and said movementrestraining means comprises two spaced-apart restrictions arranged insaid passageway, said ball being located between said restrictions. 27.A corrosion sensor according to claim 24 wherein said sight glass meanscomprises a glass dome forming a fluid chamber and said ball is locatedin said chamber and free to move within said chamber.